(This is the second of four posts detailing the mods that I have made to my CharGriller Smoker Pro.)
This mod helps contain heat by reducing the amount of hot air that escapes from a standard CG Smoker.
It places a gasket on all four sides that are exposed when the two halves of the cooking chamber open.
Three sides of the gasket are installed on the upper half of the grill: The left, right and back sides. The grill construction makes it difficult to put the front side on the upper half, so it is installed on the bottom.
The gasket material chosen is 5/8" fiber glass rope gasket material intended for wood stoves. On the front and sides the material is installed in a Z-bar channel. On the rear, it is compressed between the upper and lower halves without extra support.
The Z-bar material is extruded aluminum 1/2"x7/16"x1/2" with a thickness of 0.050". The only known source for this is http://www.tamlyn.com/index_files/AluminumProducts.htm
Overview of Gasket Placement
See the material on the edges of the upper half and in the foreground just behind the front shelf.
The Aluminum Z-Bar Material
Contains the gasket material in the area between itself and the wall of the cook chamber.
Detail of the front gasket
Showing the rivet mounting, the glass rope (before the end was trimmed and gooped to restrain it), the cut out for the shelf bracket. And yes, it has been painted with High Temp paint.
Detail of the side gasket
From the inside of the cooker, showing the riveted mounting and the glass rope material. Not visible, 1/4" dowel laid behind the rope to shim it out for better contact. Also not visible, high temp RTV holding the gasket in the channel.
Side gasket from the front
Also visible is the stack extension of 3" flexible vent tube. The tube is secured at the grill level by inserting a 'connector' segment of aluminum sheet and screwing into that through the cover.
Also visible is the back side of the replacement thermometer. It is installed in a 13/16" hole in a nominal 1-1/2" Knockout plug (electrical aisle). The knockout plug snaps into the existing hole.
Detail of the Gasket Transition from the Side to the Rear
A single piece of gasket material is used, down the left side, across the back and up the right, to minimize opportunities for slippage.
The rear section is attached directly to the back of the upper half (after suitable cleaning) with high temp RTV. It is squeezed between the two halves when the chamber is closed.
Detail of Hinge Washer
Adding a fender washer or other spacer between the hinge parts of the upper and lower halves (on both sides) takes up almost all left-right slop on the lid. (YMMV). This makes the points of contact on closing much more consistent, which results in a better seal against the gasket.
Initially, there were a number of leaks still visible with a smokey fire. With more time in place (and a few judicious strokes with the dead blow hammer) the seal is quite good.